Structure forming apparatus

ABSTRACT

A method of forming a continuous structure includes the steps of preselecting a liquid reactive resin forming material, a particulate solid additive material and a porous blanket. The additive particles are mixed with the liquid resin forming material substantially continuously in a proportion significantly greater than that of the liquid resin forming material. Substantially all of the additive particles are encapsulated with the liquid resin forming material to a preselected thickness. A pool of the resulting mixture is formed on the blanket. The blanket is advanced at a rate sufficient to create movement of the additive particles within the pool and maintain the additive particles in suspension. Part of the liquid resin forming material is migrated through the blanket substantially uniformly prior to gelling of the liquid resin forming material to form a continuous resin matrix within the blanket. Also, apparatus forming the structure as well as the structure itself.

This application is a continuation-in-part of application Ser. No.870,927, filed Apr. 20, 1992, now U.S. Pat. No. 5,330,603, which in turnis a continuation-in-part of application Ser. No. 753,344, filed Aug.30, 1991, now U.S. Pat. No. 5,145,282, which in turn is acontinuation-in-part of application Ser. No. 521,442, filed May 10,1990, now U.S. Pat. No. 5,049,006, which in turn is acontinuation-in-part of application Ser. No. 417,501, filed Oct. 5,1989, now U.S. Pat. No. 4,955,760, which in turn is acontinuation-in-part of application Ser. No. 235,205, filed Aug. 23,1988, now U.S. Pat. No. 4,872,784.

This invention relates to a novel continuous structure forming methodand apparatus and to a new continuous structure produced thereby.

The inventions of the applicant's early patents listed above providenovel methods and apparatus to produce at a job site structures such asliners and pipe for the collection, storage and/or distribution of waterand other liquids. The apparatus employed, which normally is transportedto a job site, is complex and sophisticated requiring major capitalinvestment.

The invention of applicants' latest application listed above, Ser. No.870,927, filed Apr. 20, 1992, provides a novel method and structure thatcan be produced with a minimum of machinery at the job site. Thus, thestructure and method of the invention can be employed efficiently andeconomically for patching and for small jobs even at remote locations.

While the applicant's earlier patents mention the use of recycled orwaste materials as additives in structures, most efforts of others havebeen directed to separating the waste into its primary components andthe combining of similar materials into the same product again. Variousgovernmental and private agencies have provided incentives such assubsidies and grants in attempting to develop commercially feasibleproducts and procedures for recycling waste. To date, only very fewwaste materials are routinely recycled on an economical basis.

The present invention provides a novel method, apparatus and structurewhich overcome the shortcomings of previous expedients. In addition, themethod, apparatus and structure provide features and advantages notfound in earlier technology.

The structure produced with the method and apparatus of the inventioncan include major proportions of recycled, waste or other materialswhich are readily available at a job site. These structures are of highquality and may exhibit properties not usually found in products formedwith conventional ingredients.

The method of the present invention may be conducted by individuals withonly limited mechanical skills and experience. Structures can beproduced by such individuals safely and efficiently without supervision.The configuration and composition of the structure can be changedeasily.

The method of the invention can be modified to form a variety ofdifferent structures. Variations in physical dimensions, composition andsurface appearance, etc. can be achieved. Even with such changes,uniform high quality can be maintained without difficulty.

A novel method of the present invention for forming a continuousstructure includes the steps of preselecting a liquid reactive resinforming material, a particulate solid additive material and a porousblanket. The additive particles are mixed with the liquid resin formingmaterial substantially continuously in a proportion significantlygreater than that of the liquid resin forming material. Substantiallyall of the additive particles are encapsulated with the resin formingmaterial to a preselected thickness.

A pool of the resulting mixture is formed on the porous blanket. Theblanket is advanced at a rate sufficient to create movement of theadditive particles within the pool and maintain the additive particlesin suspension. Part of the liquid resin forming material is migratedthrough the blanket substantially uniformly prior to gelling of theliquid resin forming material to form a continuous resin matrix withinthe blanket.

The additive particles advantageously are mixed with the liquid resinforming material as it is passed continuously through an elongatedmixing chamber. Preferably, the mixture is deposited on the blanket in areciprocating motion across the width of the blanket. The pool of themixture advantageously is confined on the blanket with an elongatedbarrier positioned close thereto and substantially transverse to thedirection of blanket advance.

Preferably, pressure is applied to the blanket after it passes thebarrier. The pressure advantageously is applied simultaneously across anentire width of the blanket. A preselected pattern may be formed on asurface of the blanket while pressure is applied thereto, preferablyalong an extended length of the blanket, such as by applying pressurefor an extended period of time.

A plastic film may be disposed between the barrier and the mixture withthe film advantageously moving past the barrier and preferably being ofextended length and remaining in contact with a surface of the blanket.The film may be perforated to facilitate the removal of air and in somesituations to permit liquid resin forming material to pass therethroughto adhere the structure to an adjacent surface if desired.

Benefits and advantages of the novel method, apparatus and structure ofthe present invention will be apparent from the following description ofthe accompanying drawings in which:

FIG. 1 is a side view of one form of mobile structure forming apparatusof the present invention;

FIG. 2 is an enlarged fragmentary side view partially in section ofanother form of structure forming apparatus of the invention;

FIG. 3 is an enlarged fragmentary cross sectional view of the structureof the invention shown in FIG. 1;

FIG. 4 is a fragmentary side view of other forms of raw materialsupplying and mixing portions of the apparatus of the invention;

FIG. 5 is a schematic illustration of a different form of mobilecontinuous structure forming apparatus of the invention;

FIG. 6 is a schematic illustration of a further form of structureforming apparatus of the invention; and

FIG. 7 is a schematic illustration of another form of structure formingapparatus of the invention.

As shown in the drawings, one form of novel mobile continuous structureforming apparatus 11 of the present invention includes a supportingportion 12, a raw material supplying portion 13, a mixing portion 14, amatrix forming portion 15 and a control portion 16.

The supporting portion 12 of the structure forming apparatus 11 includesat least one base section 20. Carriage means 21 operatively associatedwith base section 20 includes at least one transverse axle assembly 22,and as shown in FIG. 1, two axle assemblies 22,23 with wheels 24,25mounted on free ends 26,27 thereof.

The raw material supplying portion 13 of the apparatus 11 includes aplurality of reservoirs 29,30,31 operatively connected with thesupporting portion 12. The reservoirs are connected independently withthe mixing portion 14 through flexible conduit means 32,33,34. The rawmaterial supplying portion advantageously also includes a gravity feedhopper 36 adjacent the mixing portion 14 and preferably heating means 37along the length of the flexible conduit means 32-34.

The mixing portion 14 of the structure forming apparatus 11 of theinvention includes a generally vertically oriented elongated mixingchamber 39 mounted on the base section 20 adjacent blanket support means40. A first rotatable mixing element 41 is disposed within an uppersection 42 of the mixing chamber as shown in FIG. 2.

The mixing chamber 39 also includes a lower section 43 which preferablyis disposed at an obtuse angle to the upper section. A second openrotatable mixing element 44 is disposed within the lower section 43 ofthe mixing chamber 39.

Advantageously, the hopper 36 is connected to the lower section 43 ofthe mixing chamber 39 adjacent the intersection 45 of the lower section43 with the upper section 42. The first and second rotatable mixingelements 41,44 respectively are centrally aligned within the upper andlower sections 42,43 of the mixing chamber 39.

The matrix forming portion 15 of the apparatus 11 includes mixturedistributing means 50 adjacent an outlet 51 of the mixing chamber 39 andthe blanket support means 40. Pressure applying means 52 is disposedsubsequent to the mixture distributing means 50. Advantageously, thematrix forming portion 15 includes means 53 reciprocating the outlet 51of the mixing chamber across the width of a blanket 54 from roll 55passing thereunder.

The mixture distributing means 50 preferably also includes an elongatedbarrier member 56 disposed closely adjacent to the path of blanket 54advancing through the apparatus and substantially perpendicular to thedirection of blanket advance. Advantageously, the barrier member 56 asshown is an elongated blade member 57 inclined to the blanket in thedirection of blanket advance. Plastic film dispensing means shown asfilm supply 58 preferably is disposed adjacent the barrier member 56.

The matrix forming portion 15 advantageously includes a shallow traymember 59 disposed below the outlet 51 of the mixing chamber 39 andbelow the path of the blanket 54 through the apparatus. Preferably, thetray member is disposed in a plane substantially parallel to alongitudinal plane through the lower section 43 of the mixing chamber.Advantageously, the tray member 39 is connected to base section 20through pivot connectors 60 to simplify orientation of the tray.

The pressure applying means 52 preferably includes at least one rollershown in FIG. 1 as opposed rollers 61,62 disposed perpendicular to thepath of the blanket 54 and extending beyond edges of the blanket. Roller61 and/or 62 advantageously includes a patterned surface.

Alternatively, or in addition, the pressure applying means 52 mayinclude a belt 63 extending along the path of the blanket andparticularly cooperating belts 63,64 disposed above and below theblanket with one of the belts being a pattern forming belt. Mostadvantageously, cooperating belts 63,64 extending along the blanket aredisposed in planes substantially parallel to tray member 59.

A cutter member 65 (FIG. 2) may be located along the path of the blanket54. Also, one or more rotatable wheels 66 preferably are mounted onbrackets (not shown) extending forwardly from the base section 20. Thesewheels are oriented to press edges of the structure against a supportingsurface. Preferably, the wheels include hollow spoke members 67 whichinclude pins or nails with mechanisms (not shown) that drive the pinthrough a structure edge and into the underlying supporting surface tofix the position of the structure.

To form a structure of the invention employing apparatus 11 as shown inFIG. 1, a liquid reactive resin forming material is advanced from areservoir 30 through a conduit 33 into upper section 42 of mixingchamber 39. Simultaneously, other minor ingredients e.g. colors,catalysts, etc. from reservoir 31 advance through conduit 34 into uppersection 42 and are mixed with the resin forming material advancingtherethrough by first rotatable mixing element 41.

The resulting liquid mixture thereafter flows through the lower section43 of the mixing chamber wherein a particulate solid additive materialfrom hopper 36 flows into an upper end of the lower section 43. Theadditive particles join the liquid resin forming material advancingtherealong and are mixed therewith by second open rotatable mixingelement 44.

The additive particles are mixed with the liquid resin forming materialsubstantially continuously in a proportion significantly greater thanthat of the resin forming material. During this mixing operation,substantially all of the additive particles are encapsulated with theliquid resin forming material to a preselected thickness.

The resulting mixture being delivered from outlet 51 of the mixingchamber 39 passes onto blanket 54 as it advances over tray member 59.With barrier member 56 closely adjacent to the blanket and disposedtransversely across the width thereof (FIGS. 1 and 2), a pool 69 of themixture collects behind the barrier member. The blanket is advanced at arate sufficient to create movement of the additive particles within thepool to ensure complete encapsulation and also to maintain the particlesin suspension so the mixture adhering to the blanket is homogeneous.

As the blanket advances under the barrier member excess mixture isremoved and a substantially uniform preselected thickness is retained onthe blanket. Thereafter, part of the liquid resin forming material isallowed to migrate through the blanket to form a cross section asillustrated in FIG. 3 which will be described hereafter.

If it is desired to form a preselected patterned surface on the treatedblanket combination, the blanket is passed into contact with a patternedroller 61 or belt 63 or a combination of rollers 61,62 or belts 63,64.Advantageously, a pattern is formed on the blanket surface by applyingpressure to the blanket for an extended period of time. This may beaccomplished by using cooperating belts 63,64 of considerable length.

To produce high quality structures of the invention, it is importantthat all of the steps be carefully coordinated by control portion 16.The control portion 16 of the structure forming apparatus 11 of theinvention includes programmable memory means 46 and actuating means 47responsive thereto in combination with coordinating means 48 to controlthe operation of pumps, valves and drives. Preferably, the coordinatingmeans includes a process controller 49 that initiates changes in theflows of materials and speeds of drives to bring variations therein backto the rates specified in the programs present in the memory 46.

This coordination commonly is achieved through the transmission ofinformation such as digital pulses from the monitors and/or sensors atthe control components to the process controller 49. The operatinginformation is compared with the preselected programming parametersstored in the memory 46. If differences are detected, instructions fromthe controller change the operation of the components to restore thevarious operations to the preselected processing specifications.

As shown in FIG. 3, a cross section of a typical structure of theinvention 71 includes a continuous upper plastic film 72 and an upperlayer 73 including a plurality of encapsulated solid particles 74 e.g.particles from grinding discarded tires, within a continuous resinmatrix 75. The resin matrix extends downwardly through blanket 77 andforms a thinner resin rich lower layer 78 including a few very smallsolid particles 79 disposed primarily closely adjacent to the blanket.The structure shown also includes a lower plastic film 81 which forcertain applications may include perforations or other spaced openings82 through which resin 83 extends.

The inclusion of upper and/or lower plastic films may facilitate theinstallation of novel structures of the invention under adverse weatherconditions or below water or other liquids. Also, the flowing of resinthrough film openings 82 can provide adhesion of the structure to asubsurface (not shown).

Another method for obtaining a suitable mixture for application to ablanket employs apparatus 84 of the invention as shown in FIG. 4. Apreformed film 85 (formed as described in applicant's copendingapplication Ser. No. 870,927, filed Apr. 20, 1992) has a firstpreselected pattern including a plurality of independent sections spacedfrom a second preselected pattern of independent sections. One of thepatterns includes independent sections with solid additive particles anda second preselected pattern of independent sections including a liquidreactive resin forming material.

As shown in FIG. 4, a roll 86 of the above preformed film 85 is passedbetween crushing rollers 87 which intermix the solid additive particlesinto the liquid resin forming material. The resulting mixture is carrieddownwardly with the film into contact with a blanket 88 advancingthereunder. A pool 89 of the mixture is formed between the film and theblanket by the restraint of barrier member 90.

The blanket is advanced at a rate sufficient to create movement of thesolid additive particles within the pool to ensure encapsulation thereofand maintain the additive particles in suspension. The blanket with themixture and a film on the upper surface passes under barrier member 90to form a uniform layer of preselected thickness and then is advancedalong the apparatus in the manner described with regard to the apparatusof FIG. 1. The structure nay be used in the same or differentapplications as desired with similar results.

FIG. 5 illustrates the use of continuous structure forming apparatus ofthe invention in combination with a power shovel. The apparatus 92 issuspended from a bucket 93 of a shovel 91 movable along a blanket of aditch 94. The apparatus lays continuous lengths of the structure of theinvention across the ditch from one bank to the other in an overlappingrelationship.

One end of each length of the structure is staked to the ditch bank andthe structure delivered from the apparatus which is disposed closely tothe ditch surface. This arrangement is especially useful under windyconditions.

FIG. 6 illustrates another arrangement for using a structure formingapparatus of the invention. In this arrangement, apparatus 95 ispositioned in the bottom of a ditch 96. As the apparatus moves along theditch bottom, the apparatus positions lengths of the structuretransversely of the ditch. Raw materials are supplied to the apparatusfrom a vehicle 97 including raw material reservoirs 98 through flexibleconduits 99.

FIG. 7 illustrates an end view of a structure forming apparatus 101straddling a narrow ditch 102 with banks 104 as a continuous structure103 is positioned longitudinally along the ditch.

The liquid reactive resin forming material employed to producestructures of the invention is selected to be capable of reaction toform the particular resin matrix desired in the final structure.Advantageously, the resin matrix is a thermosetting resin such as apolyurethane or polyester. Should a polyurethane be desired, onereservoir may contain an isocyanate and another reservoir may contain apolyol. More commonly, the reservoirs may contain different partiallyformed materials which upon mixing interact to form the desiredpolyurethane. Examples of such partially formed materials includeso-called "A stage" resins and "B stage" resins.

Other resin forming systems may utilize a resin forming material in onereservoir and a catalyst in a second reservoir. Additional componentscan be premixed with one of the resin formers, e.g. fillers,reinforcements, colors and the like.

The particulate solid additive material is mixed with the liquidreactive resin forming material substantially continuously in aproportion significantly greater than that of the resin formingmaterial. The additive particles may be any of a wide variety ofinexpensive materials readily available at a particular job site.Natural mineral particulate materials such as sand and gravel normallyare available or can be produced simply by crushing rock at the site.

Also, materials such as waste or recycled materials which can beshredded or ground into particles of suitable size can be utilized.Particularly useful are particles formed by shredding or grindingdiscarded tires. Since the particles are encapsulated with the resinforming material and not saturated therewith many different wastematerials may be employed.

Suitable porous blankets include woven, knit, non-woven structures, etc.The blankets e.g. fabrics, mats, etc. may be formed of continuous ordiscontinuous fibers, yarns, slit ribbons and similar natural andsynthetic fibrous materials. Reinforcing members such as ropes, cablesand the like that extend longitudinally and/or transversely of theblanket centerline may be included if desired.

The above description and the accompanying drawings show that thepresent invention provides a novel method, apparatus and structure whichovercome the shortcomings of previous expedients and in addition,provide features and advantages not found in earlier technology.

The structure produced with the method and apparatus of the inventioncan include major proportions of recycled, waste or other materialswhich are readily available at a job site. These structures are of highquality and may exhibit properties not usually found in products formedwith conventional ingredients.

The method of the invention may be conducted by individuals with onlylimited mechanical skills and experience to produce high qualitystructures safely and efficiently. The method can be modified to form avariety of different structures. Variations in configuration,composition, physical dimensions and surface appearance, etc. can beachieved easily. Even with such changes, uniformity and high quality canbe maintained without difficulty.

It will be apparent that various modifications can be made in theparticular method, apparatus and structure described in detail above andshown in the drawings within the scope of the present invention. Themethod steps, apparatus components and types of materials employed canbe changed to meet specific process and structural requirements. Forexample, the number and disposition of porous blankets and patterns canbe different. These and other changes can be made in the method,apparatus and structure of the invention provided the functioning andoperation thereof are not adversely affected. Therefore, the scope ofthe present invention is to be limited only by the following claims.

What is claimed is:
 1. Mobile continuous structure forming apparatus including a supporting portion, a raw material supplying portion, a mixing portion, a matrix forming portion and a control portion; said supporting portion including at least one base section, carriage means operatively associated with said base section; said raw material supplying portion including a plurality of reservoirs operatively connected with said supporting portion, said reservoirs being connected independently with said mixing portion through flexible conduit means, blanket support means mounted on said base section, a continuous blanket advancing from said blanket support means in a direction along a path through said matrix forming portion; said mixing portion including a generally vertically oriented elongated enclosed mixing chamber mounted on said base section adjacent said blanket support means, said mixing chamber including an upper liquid mixing section with a first rotatable mixing element disposed therein, said mixing chamber including a lower liquid/solid particle mixing section disposed below said upper mixing section and connected thereto at an obtuse angle, a solid particle feeding hopper connected to said lower mixing section at a point thereon above its connection with said upper mixing section, a second open rotatable mixing element disposed within said lower mixing section of said mixing chamber; said matrix forming portion including mixture distributing means adjacent an outlet of said mixing chamber, pressure applying means disposed subsequent to said mixture distributing means; said control portion including programmable memory means, coordinating means, sensing means, actuating means, and circuitry transmitting signals from said sensing means to said coordinating means for comparison with said memory means and activation of said actuating means to form and maintain a uniform resin matrix forming mixture with a preselected major proportion of solid particles and to form with said mixture a continuous resin matrix within said blanket.
 2. Mobile continuous structure forming apparatus according to claim 1 including an elongated barrier member disposed closely adjacent to the path of a blanket advancing through said apparatus and substantially perpendicular to the direction of blanket advance.
 3. Mobile continuous structure forming apparatus according to claim 2 wherein said elongated barrier member is an elongated blade member inclined to said blanket in the direction of blanket advance.
 4. Mobile continuous structure forming apparatus according to claim 2 including plastic film dispensing means disposed adjacent said barrier member.
 5. Mobile continuous structure forming apparatus according to claim 1 including a shallow tray member disposed below said mixture distributing means and below the path of said blanket through said apparatus.
 6. Mobile continuous structure forming apparatus according to claim 5 wherein said tray member is disposed in a plane substantially parallel to a longitudinal plane through said lower mixing section of said mixing chamber.
 7. Mobile continuous structure forming apparatus according to claim 6 including cooperating belts extending along said blanket disposed in planes substantially parallel to said tray member.
 8. Mobile continuous structure forming apparatus according to claim 1 wherein said pressure applying means includes at least one roller disposed perpendicular to the path of said blanket and extending beyond edges of said blanket.
 9. Mobile continuous structure forming apparatus according to claim 8 wherein said roller includes a patterned surface.
 10. Mobile continuous structure forming apparatus according to claim 1 wherein said pressure applying means includes a belt extending along the path of said blanket.
 11. Mobile continuous structure forming apparatus according to claim 10 wherein said pressure applying means includes cooperating belts disposed above and below said blanket.
 12. Mobile continuous structure forming apparatus according to claim 11 wherein one of said belts is a pattern forming belt.
 13. Mobile continuous structure forming apparatus according to claim 1 wherein said raw material supplying portion includes a gravity feed hopper for said solid particles.
 14. Mobile continuous structure forming apparatus according to claim 1 wherein said raw material supplying portion includes heating means disposed along a length of said flexible conduit means.
 15. Mobile continuous structure forming apparatus according to claim 1 wherein said first and second rotatable mixing elements respectively are aligned within said upper and lower mixing sections.
 16. Mobile continuous structure forming apparatus according to claim 1 including reciprocating means distributing said mixture across a width of said blanket. 